metal signs for house $12.00 After coming to terms with 1/8", 1/4" and 1/2" steel, I went in the other direction and tried to join some 26ga sheet metal (1018). Not much luck with that. The only thing that worked out consistently was spot welding by sandwiching two pieces, setting max amps to 45 and flooring the pedal for 1 second.
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Try another by drilling it out a little bigger to clean the hole up and make it easier to weld. In either case, use the copper backer you hammered out of old pipe. Oh, and experiment with different settings, different size holes and using the backer on scrap first.
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The E6013 welding rod is the best to stick weld thin mild steel and is known as a sheet metal rod. An E6013 has a flux covering with high amounts of rutile. Rutile creates the smoothest arc with light penetration that won’t burn through the joint as easily as other rods.
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